ComfoAir 200 Installer manual

Cooling Fresh Air Clean AirHeating

ComfoAir 200Installer manual

EN - II

All rights reserved.This manual has been compiled with the utmost care. The publisher cannot be held liable for any damage caused as a result of missing or incorrect information in this manual. In case of dis putes the Dutch version of these instructions will be binding.

III - EN

Table of Contents

Preface ............................................................................................................................................................. 1

1 INTRODUCTION .............................................................................................................................................. 11.1 Warranty and liability .......................................................................................................................... 1

1.1.1 Guarantee conditions ............................................................................................................... 11.1.2 Liability ...................................................................................................................................... 1

1.2 Safety ................................................................................................................................................... 21.2.1 Safety regulations ..................................................................................................................... 21.2.2 Safety provisions and measures .............................................................................................. 21.2.3 Pictograms used ....................................................................................................................... 2

2 FOR THE FITTER ............................................................................................................................................ 32.1 ComfoAirconfiguration ...................................................................................................................... 32.2 Technicalspecifications ..................................................................................................................... 42.3 Dimension sketch ............................................................................................................................... 62.4 Installation conditions ........................................................................................................................ 72.5 Installation of the ComfoAir ............................................................................................................... 7

2.5.1 Transport and unpacking ......................................................................................................... 72.5.2 Checking the delivery ............................................................................................................... 7

2.6 MountingoftheComfoAir .................................................................................................................. 72.6.1 Mounting on the ceiling ............................................................................................................ 72.6.2 Mounting on the wall ................................................................................................................ 82.6.3 Connection of the air ducts ...................................................................................................... 82.6.4 Connection of the condensation drain .............................................................................................9

2.7 CommissioningtheComfoAir ........................................................................................................... 92.7.1 Display on the unit .................................................................................................................. 102.7.2 P menus for the installer ........................................................................................................ 11

2.8 Programmingairspecifications ...................................................................................................... 152.9 Maintenance by the installer ............................................................................................................ 16

2.9.1 Inspecting and cleaning the heat exchanger ........................................................................ 162.9.2 Inspecting and cleaning the fans ........................................................................................... 17

2.10 Malfunctions ...................................................................................................................................... 172.10.1 Malfunction alerts on the digital operating device ............................................................... 172.10.2 3-position switch with malfunction indicator ........................................................................ 182.10.3 What to do in the event of a malfunction / Troubleshooting ................................................ 192.10.4 Malfunctions (or problems) without alerts ............................................................................. 29

2.11 Service parts ...................................................................................................................................... 302.12 Wiringdiagram:ComfoAir200Basic–LEFT-HANDversion ........................................................ 312.13 Wiringdiagram:ComfoAir200Basic–RIGHT-HANDversion ..................................................... 322.14 Wiringdiagram:ComfoAir200Luxe–LEFT-HANDversion ......................................................... 332.15 Wiringdiagram:ComfoAir200Luxe–RIGHT-HANDversion ....................................................... 342.16 EEC declaration of conformity ......................................................................................................... 35

EN - IV

1 - EN

Preface

Carefully read this manual before use.

This manual provides all the information required for safe and optimal installation and maintenance of the ComfoAir 200. It is also intended as a reference for servicing, so that this can be carried out in a respon-sible manner. The device is subject to continuous de-velopment and improvement. As a result, the Com-foAir 200 may slightly differ from the descriptions.

1 IntroductionThe device's name is ComfoAir 200. In the following it will be referred to as ComfoAir.The ComfoAir is a balanced ventilation system with heat recovery in order to create healthy, balanced and energy-efficient ventilation in houses. The Com-foAir has a CE marking on the identification plate. The identification plate can be found on top of the ComfoAir.

1.1 Warranty and liability

1.1.1 GuaranteeconditionsThe ComfoAir is covered by a manufacturer’s war-ranty for a period of 24 months after fitting up to a maximum of 30 months after the date of manufac-ture. Warranty claims may only be submitted for ma-terial faults and/or construction faults arising during the warranty period. In the case of a warranty claim, the ComfoAir must not be dismantled without written permission from the manufacturer. Spare parts are only covered by guarantee, if they were supplied by the manufacturer and have been installed by an ap-proved installer.

The warranty becomes invalid if: The guarantee period has elapsed; The device is used without filters; Parts are used that have not been supplied by the

manufacturer; Non-authorised changes or modifications have

been made to the unit.

1.1.2 LiabilityThe ComfoAir has been designed and manufactured for use in balanced ventilation systems incorporating Zehnder heat recovery systems. Any other applica-tion is seen as inappropriate use and can result in damage to the ComfoAir or personal injury, for which the manufacturer cannot be held liable.The manufacturer is not liable for any damage origi-nating from: Non-compliance with the safety, operating and

maintenance instructions in this manual; The use of components not supplied or recom-

mended by the manufacturer. Responsibility for the use of such components

lies entirely with the installer; Normal wear and tear.

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1.2 Safety

1.2.1 Safety regulationsAlways comply with safety regulations in this manual. Non-compliance with the safety regulations, warn-ings, notes and instructions in this manual can cause personal injury or damage to the ComfoAir. The ComfoAir may only be installed, connected,

rendered operational and maintained by an ap-propriately approved installer, unless otherwise indicated in this manual;

Installation of the ComfoAir must be carried out in accordance with the general and locally applica-ble construction, safety and installation instruc-tions of the local council, electricity and water boards or other agencies;

Observe the safety regulations, warnings, com-ments and instructions as prescribed in this man-ual at all times;

Keep this manual with the ComfoAir throughout its life;

Instructions with regard to cleaning or replacing the filters of the intake and exhaust valves must be carefully observed;

The specifications stated in this document may not be changed;

Modifying the ComfoAir is not allowed; The ComfoAir is only suitable for connection to

230V 50Hz mains; It is recommended to take out a maintenance

contract so that the device is checked on a regu-lar basis. The supplier can provide a list of regis-tered installers nearby.

1.2.2 Safety provisions and measures The ComfoAir cannot be opened without using

tools; It should not be possible to touch the fans, there-

fore ducting must be connected to the ComfoAir at a minimum duct length of 900mm.

1.2.3 Pictograms usedThe following pictograms are used in this manual:

Point of attention.

Risk of: - damage to the device; - performance of the device is compro-

mised if instructions are not observed carefully.

Risk of personal injury for the user or installer.

3 - EN

2 For the Fitter2.1 ComfoAir configuration

The standard ComfoAir configuration consists of: External casing (A) of coated sheeting; Interior (B) of high-quality, expanded polypropylene EPP; 4 connections (C) for the air ducts; 2 plate filters (D) for air purification. Filter classification: outside air G4, return air G4; 2 energy-efficient DC motors (E) with high-efficient fan; HE (High efficient) heat exchanger (F); Display (G) to read data, and for programming procedures (optional); Control circuit board (H) with connections for the fans, the bypass, the Pre heater, temperature sensors (T1 to

T4), the 3-position switch with or without malfunction indicator (optional) and the bathroom switch (optional); Connector panel (H) with all the extra connections of the ComfoAir Luxe; Identification plate (I) detailing information on the ComfoAir (not visible); Condensation drain (J) to drain the condensation of the warm return air; Sticker (K) detailing the air connections (not visible); Cable for power supply (not visible); 2 Filtercaps (M); 4 Ceiling mounting brackets (N) or 1 Wall mounting bracket (not visible).

EN - 4

2.2 Technicalspecifications

ComfoAir200nL(normalairvolumes)Position Ventilation capacity Power

Absent Setting 20 m3/h at 3 Pa 9 WLow Setting 70 m3/h at 10 Pa 17 W

Medium Setting 120 m3/h at 30 Pa 30 WHigh Setting 185 m3/h at 68 Pa 68 WMaximum 255 m3/h at 125 Pa 143 WPosition Ventilation capacity Current

Absent Setting 20 m3/h at 3 Pa 0.08 ALow Setting 70 m3/h at 10 Pa 0.14 A

Medium Setting 120 m3/h at 30 Pa 0.25 AHigh Setting 185 m3/h at 68 Pa 0.55 AMaximum 255 m3/h at 125 Pa 1.10 A

ElectricityPower supply 230/50 V/Hz

Cos.phi 0.48 - 0.57

Supplyfannoiselevel(at0m)Position Ventilation capacity Soundpower

Absent Setting 20 m3/h at 3 Pa 37 dB(A)Low Setting 70 m3/h at 10 Pa 49 dB(A)

Medium Setting 120 m3/h at 30 Pa 59 dB(A)High Setting 185 m3/h at 68 Pa 66 dB(A)Maximum 255 m3/h at 125 Pa 73 dB(A)

Exhaustfannoiselevel(at0m)Position Ventilation capacity Soundpower



5 - EN

ComfoAir200HL(highairvolumes)Position Ventilation capacity Power

Absent Setting 20 m3/h at 3 Pa 9 WLow Setting 90 m3/h at 13 Pa 20 W

Medium Setting 185 m3/h at 68 Pa 68 WHigh Setting 245 m3/h at 120 Pa 128 WMaximum 255 m3/h at 125 Pa 143 WPosition Ventilation capacity Current

Absent Setting 20 m3/h at 3 Pa 0.08 ALow Setting 90 m3/h at 13 Pa 0.16 A

Medium Setting 185 m3/h at 68 Pa 0.55 AHigh Setting 245 m3/h at 120 Pa 0.99 AMaximum 255 m3/h at 125 Pa 1.10 A

ElectricityPower supply 230/50 V/Hz

Cos.phi 0.48 - 0.57

Supplyfannoiselevel(at0m)Position Ventilation capacity Soundpower



Exhaustfannoiselevel(at0m)Position Ventilation capacity Soundpower



GeneralSpecificationsHE Exchanger Material Polystyrene

Interior Material (E)PP / ABS Thermal Yield 95%

Mass 30 kg

EN - 6

2.3 Dimension sketch

LEFT RIGHTCONDENSATION DRAIN

7 - EN

2.4 Installation conditionsIn order to determine whether the ComfoAir can be installed in a certain area, the following aspects must be taken into account: The ComfoAir must be installed according to the

general and locally applicable safety and installa-tion regulations of power and water companies, as well as the instructions in this manual.

The system must be fitted to allow sufficient room around the ComfoAir for the air connections and supply and exhaust ducts as well as for carrying out maintenance activities.

The ComfoAir must be installed in a frost-free space. The condensation must be drained off frost-free, at a gradient and incorporate a 'U' bend.

We do not recommend installing the Com-foAir in areas with a higher average humidity (such as bathroom or toilet). This will prevent condensation on the outside of the ComfoAir.

The room must offer the following provisions: - Air duct connections. - 230V electrical connection. - Provisions for the condensation drain. - Wiring for a wired 3-position switch (optional). A gap should be left near the doors in order to

ensure effective and draughtfree airflow in the house. A gap under the inside doors must be at least 10mm.

If these openings are obstructed, due to draught excluders or deep-pile carpet, the airflow in the house will stagnate. As a result, system performance will be compromised or fail altogether.

2.5 Installation of the ComfoAir

2.5.1 Transport and unpackingTake the necessary precautions when transporting and unpacking the ComfoAir.

Make sure the packing material is disposed of in an environmentally friendly manner.

2.5.2 Checking the deliveryContact your supplier immediately in case of dam-age or an incomplete delivery. The delivery should include: ComfoAir; Check the identification plate to ensure that it is

the required type. Ceiling mounting set; Wall mounting bracket; Documentation.

The ComfoAir is supplied in the following types:Type

ComfoAir 200 L BasicComfoAir 200 R BasicComfoAir 200 L LuxeComfoAir 200 R LuxeComfoAir 200 L Luxe PHComfoAir 200 R Luxe PH

Meaning of the suffixes: L = Left version R = Right version PH = Contains a pre heater by default. Luxe = Contains a connection board

with extra function by default. ComfoSense panel (optional) can be ordered sepa-rately.

2.6 Mounting of the ComfoAirThe ComfoAir can be mounted two ways: On the ceiling; On the wall.

2.6.1 Mounting on the ceilingMount the ComfoAir to a ceiling with a minimum mass of at least 200 kg/m2.

BA

C

1. Fasten the four mounting brackets (A) (using the screws supplied) to the sides of the ComfoAir.

2. Fasten the two spacer brackets (C) (using the screws supplied) to the top of the ComfoAir on the side of the condensation drain (B). As long as the ceiling is level, this ensures a run-off of 2% to the condensation drain.

3. Mark the position of the mounting points on the ceiling.

4. Mount four pieces of studding (M8 or M10) exten-ding 290 cm below the ceiling.

5. Screw suitable (securing) rings and nuts on the four rods.

6. Hang the unit on the rods and then screw the locknuts tight.

Allow a minimum 2% run-off to the condensation drain. If the ceiling is horizontal, the spacer brak-kets will automatically ensure that the ComfoAir hangs at the correct angle.

7. Mount the condensation drain to the ComfoAir with a coupling or removable pipe.

8. The air exhaust duct must be fitted with a double-walled or insulated roof passage. This prevents the formation of condensation between the roof boarding. In addition, the air exhaust duct must drain in the direction of the ComfoAir.

9. To prevent unnecessary temperature loss in eit-her the summer or the winter, we recommend fitting thermal and damp-proof insulation to the supply ducts from the ComfoAir up to the supply valves.

Ensure that there is enough room under the ComfoAir for carrying out maintenance. The ComfoAir does not require any space at the sides for effective operation.

EN - 8

Do not mount the side of the ComfoAir against the wall due to the risk of impact sound.

2.6.2 Mounting on the wall

Mount the ComfoAir against a wall with a minimum mass of 200 kg/m2.1. Using a spirit level, fix the mounting bracket ho-

rizontally to the wall. Use M8 anchor bolts. Make sure there is enough space under the ComfoAir to mount the U bend.

2. Hang the unit on the mounting bracket.3. Mount the condensation drain under the Com-

foAir. The stated dimension of 235 mm is an in-dication only, and is dependent on the type of condensation drain selected.

Make sure to leave a minimum space of 1 metre in front of the ComfoAir for carrying out maintenance.The ComfoAir does not require any space at the si-des for effective operation.

Do not mount the side of the ComfoAir against the wall due to the risk of impact sound.

2.6.3 Connection of the air ductsThe following aspects must be taken into account, while installing the air ducts: Install the air exhaust duct so it drains in the di-

rection of the ComfoAir; Insulate the outside air supply and the air ex-

haust duct between the roof/wall passage to render the ComfoAir damp proof. This prevents the formation of condensation on the outside of the ducts;

To prevent unnecessary temperature loss in ei-ther the summer or the winter, we recommend fitting thermal and damp-proof insulation to the supply ducts from the ComfoAir up to the supply valves;

Install the air ducts with a minimum ø of 125 mm, as little air resistance as possible and free from air leakage;

Install a silencer of at least 1m straight directly onto the supply and return air connections. For relevant advice, please contact Zehnder;

When using flexible channels only Zehnder channel systems may be used. Any other flexible channel will disturb the basic operating principle of the balanced ventilation system;

We recommend that the ventilation system is fitted with intake and exhaust valves made by Zehnder.

Supply air Return air

Exhaust air Outside air

ComfoAir 200 - LEFT

Return air Supply air

Outside air Exhaust air

ComfoAir 200 - RIGHT

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2.6.4 Connection of the condensation drain

Standard heat exchanger

min

60

mm

min

60

mm

20 mm

ComfoAir 200 - LEFT

min

60

mm

min

60

mm

20 mm

ComfoAir 200 - RIGHT

Warm exhaust air is cooled by the outside air in the heat exchanger. This causes the moisture in the in-door air to condense in the heat exchanger. The con-densation water created in the heat exchanger is fed

to a PVC condensation drain.The connection for the condensation drain has an ex-ternal diameter of 20 mm and a ledge of 21.2 mm. It is located underneath the ComfoAir. Connect the condensation drain, via a pipe with

coupling or hose, to the water seal (U bend) of the domestic waste-water system.

For future maintenance activities the con-densation drain must be removable.

Ensure the condensation drain pipe on ceiling-mounted units has a run-off to the U bend of at least 2%.

Position the upper edge of the water seal at least 40 mm underneath the condensation drain of the ComfoAir.

Make sure that the outer end of the pipe or tube exits is at least 60mm below the water level.

Ensure that the water seal connected to the domestic waste-water system is always full of water. This prevents the ComfoAir from sucking in any leakage air.

Enthalpy heat exchangerWhen the ComfoAir is fitted with an enthalpy ex-changer the moisture from the indoor air is transferred to the outside air. In this case there is no condensate which must be drained from the ComfoAir. Therefore a condensation drain is not necessary when an en-thalpy exchanger is fitted.

Ensure that the condensation drain is sealed. This prevents the ComfoAir from sucking in any leakage air.

The condensation drain can be sealed with a standard screw-cap.

2.7 Commissioning the ComfoAirAfter installation, the ComfoAir must be commis-sioned.

This can be done via the P menus on the digital op-erating device. These P menus can be used to enter various settings (ventilation programmes, in particu-lar) for the ComfoAir. An overview of the available P menus is given below:Menu OptionsP1 Reading statuses (from menu P2)P2 Setting time delaysP3 Setting and reading the ventilation

levelsP4 Setting and reading the temperatu-

resP5 Setting additional programmesP6 Setting additional programmesP7 Reading and resetting malfunctions

(and system information)

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Menu OptionsP8 Setting the RF input and analogue

inputs (0-10V)P9 Reading statuses (from menu P5

and P6)

P menus P1, P2 and P9 can be accessed by the user, mainly to read statuses and set time delays. The re-maining P menus P3 to P8 are intended solely for the installer.

The ComfoAir's bypass valve will not work for the first 4 minutes after a power cut un-less the programme mode is activated.

2.7.1 DisplayontheunitThe ComfoAir can be operated and commissioned by means of a display. The display is a digital op-erating device which is mounted on the ComfoAir.

select menu upOK downsupply off supply on

(led green) (led green) comfort temperature

Shown in display Ventilation setting absent Ventilation setting low Ventilation setting medium Ventilation setting high Menu symbol Malfunction code (flashes) Bypass

AccesstothemenusSe-

quencePress Display Description

1 MENU P2 Time delay

2 s +

(3 seconds)P3 Press the buttons

simultaneously.

3 s P4 Temperatures

4 s P5 Settings

5 s P6 Settings

6 s P7 Malfunction / Reset / Self-test

7 s P8 0 - 10V Inputs

8 s P9 Status

Example Setting the MEDIUM POSITION of the supply fan to 40%.

Se-quence

Press Display Description

1 MENU P2 Time delay

2 s +

(3 seconds) P3 Press the buttons simultaneously.

3 OK P30 Exhaust fan Position A

4 s (6x) P36 Select P36

5 OK 50 Current setting

6 (10 x or press con-tinuously)

40 Select 40

7 OK P35 Value is 40

8 MENU P3

9 MENU 1 Fan setting

Some P menus (such as P1 and P9) can only be read.

Leaving Reading menu At action point 6 press "MENU" (instead of

"OK").

The display can not be used for setting the ventilation positions of the ComfoAir. The arrowkeys are only for setting the additional programmes.

OK

MENU

·

··

OK

MENU

·

··

OK

MENU

·

··

OK

MENU

·

··

OK

MENU

·

··

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

1

A

2

3

X X

X X

•

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2.7.2 P menus for the installer

Menus with a line at minimum and maximum value are Reading menus.

Menu P3 ¨ Setting ventilation programmes

Ventilation programme valuesSubmenu Description Minimum Maximum General

Reset

P30 Setting the capacity (in %) of the exhaust fan in ABSENT POSITION.

0% or 15% 97% nL / HL15% / 15%

P31 Setting the capacity (in %) of the exhaust fan in LOW POSITION.

16% 98% nL / HL35% / 40%

P32 Setting the capacity (in %) of the exhaust fan in MEDIUM POSITION.

17% 99% nL / HL50% / 70%

P33 Setting the capacity (in %) of the exhaust fan to HIGH POSITION.

18% 100% nL / HL70% / 90%

P34 Setting the capacity (in %) of thesupply fan to ABSENT POSITION.

0% or 15% 97% nL / HL15% / 15%

P35 Setting the capacity (in %) of thesupply fan in LOW POSITION.

16% 98% nL / HL35% / 40%

P36 Setting the capacity (in %) of thesupply fan in MEDIUM POSITION.

17% 99% nL / HL50% / 70%

P37 Setting the capacity (in %) of thesupply fan in HIGH POSITION.

18% 100% nL / HL70% / 90%

P38 Current capacity (in %) of the exhaust fan.

- - Current %

P39 Current capacity (in %) of the supply fan.

- - Current %

Menu P4 ¨ Reading the temperatures

Temperature valuesSubmenu Description Minimum Maximum General

Reset

P41 Comfort temperature 12 oC 28 oC 20 oCP45 Current value of T1

(= outside air temperature)- - Current oC

P46 Current value of T2 (= supply air temperature)

- - Current oC

P47 Current value of T3(= return air temperature)

- - Current oC

P48 Current value of T4(= exhaust air temperature)

- - Current oC

Menu P5 ¨ Setting additional programmesAdditional programme values

Submenu Description Minimum Maximum General Reset

P50 Activation of the open fire programme. 0 (= No) 1 (= Yes) 0P51 Confirming the presence of

a pre heater0 (= No) 1 (= Yes) 0

Only change if a pre heater is installed afterwards or a general reset is given.

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Additional programme valuesSubmenu Description Minimum Maximum General

Reset

P52 Setting the pre heater programme. 0; Guaranteed protection. 1; High protection. 2; Nominal protection. 3; Economy.

0 3 2

In GUARANTEED PROTECTION MODE the pre heater is switched on soonest; this level offers the best guarantee of balanced ventilation. Vice versa, in ECONOMY MODE the pre heater switches on at the last possible moment; balanced ventilation is not guaranteed in this mode.

When commissioning the ComfoAir, the pre heater programme can usually be left at level 2: NOMINAL MODE (factory setting). In areas with frequent cold spells in winter (frequent periods of -10°C or lower), level 1 should be selected: HIGH PROTECTION or even level 0: GUARANTEED PROTECTION.

P54 Confirming the presence of a bypass. 0 (= No) 1 (= Yes) 1

The standard ComfoAir configuration includes a bypass. Therefore, leave the value at ‘1’.P56 Setting the required air volume in the house.

nL: ”normal air volume”. HL: "high air volume".

nL HL HL

Setting the air volume is the starting point for programming the air specifications and setting the fans.P57 Setting the ComfoAir type.

Li = ”Left-hand version”. Re = ”Right-hand version”.

Li Re Li

With delivery the ComfoAir is correctly pre-programmed at the factory.

After a general reset the pre-programming is lost and the setting must be reset.

The correct setting is mentioned on the identification plate on top of the ComfoAir.P58 n/a 0 1 0P59 Confirming the presence of an enthalpy exchanger.

0; Enthalpy exchanger not fitted 1; Enthalpy exchanger with RH sensor. 2; Enthalpy exchanger without RH sensor.

0 (= No) 2 (= Yes) 0

Ensure the condensation drain is sealed.

If an enthalpy exchanger without a sensor is selected, then the safety programme will not be activated and malfunction alerts EA1 & EA2 will never occur.

Menu P6 ¨ Setting additional programmes

Additional programme valuesSubmenu Description Minimum Maximum General

Reset

P60 Confirming the presence of a geothermal heat exchanger. 0; Geothermal heat exchanger not fitted 1; n/a 3; Geothermal heat exchanger unregulated.

0 (= No) 3 (= Yes) 0

The ComfoAir 200 can only be fitted with an unregulated geothermal heat exchanger.

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Menu P7 ¨ Reading malfunctions (and system information)

(Malfunction) information valuesSubmenu Description Minimum Maximum General

Reset

P70 Current software version. Version number of the software (without “v”)P71 Most recent malfunction. Code in accordance with alarm and malfunction alert P72 Malfunction before the most recent one Code in accordance with alarm and malfunction alert P73 Malfunction before the most recent two Code in accordance with alarm and malfunction alert P74 Resseting malfunction(s)

Set value to '1' and press "OK" on the-display.

Set value to '1' and press "OK" on the ComfoSense panel.

0 1(= activate)

0

P75 General reset. Press "OK" on the display for at least 5

seconds to carry out a general reset. Set value to '1' and press “OK” on the

ComfoSense panel to carry out a gen-eral reset.

All original software settings are restored following a general reset.

0 1(= activate)

0

After a general reset, the ComfoAir will ask you to reset the “nL / HL” (see P56) and “Li / Re” (see P57) settings.Following a general reset, all settings and programmes need to be checked and set to the right value.

P76 Self-testing the ComfoAir 0 1(= activate)

0

• The ComfoAir will run at maximum Rotations Per Minute (RPM).• The bypass valve will open and close.• The pre heater valve will open and close after the bypass has closed (If a pre heater is fit-

ted).

P77 Resetting filter dirty counter 0 1(= activate)

0

This resets the counter that triggers a dirty filter alert on the ComfoAir. This allows the filter to be cleaned or replaced before the dirty filter alert appears.

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Menu P8 ¨ Setting the RF input and digital inputs (0-10V)

Analogue input valuesSubmenu Description Minimum Maximum General Reset

810 Analogue input 10= not fitted 1= fitted

0 1 0

811 0= controlling 1= programming (analogue input 1)

0 1 0

812 set point analogue input 1 (programming)

0 100 50

813 min. setting analogue input 1 0 99 0 814 max. setting analogue input 1 0 100 100 815 0=positive analogue input 1 1=negative set-

ting analogue input 1 0 1 0

816 read-out analogue input 1 0 100 -820 Analogue input 2

0= not fitted 1= fitted 0 1 0

821 0= controlling 1= programming (analogue input 2)

0 1 0

822 set point analogue input 2 (programming)

0 100 50

823 min. setting analogue input 2 0 99 0 824 max. setting analogue input 2 0 100 100 825 0=positive analogue input 2 1=negative set-

ting analogue input 2 0 1 0

826 read-out analogue input 2 0 100 -850 RF input 1 0= not fitted 1= fitted 0 1 0 851 0= controlling 1= programming (RF input 1) 0 1 0 852 set point RF input 1

(programming) 0 100 50

853 min. setting RF input 1 0 99 0 854 max. setting RF input 1 0 100 100 855 0=positive RF input 1 1=negative setting RF

input 1 0 1 0

856 Read-out RF input 0 100 -

15 - EN

2.8 Programming air specificationsAfter installation, the ComfoAir must be programmed.

This can be done using the air specifications of the ComfoAir above.

The default settings of the ComfoAir nL are:

Position ABSENT 15%Position LOW 35%Position MEDIUM 50%Position HIGH 70%

The default settings of the ComfoAir HL are:

Position ABSENT 15%Position LOW 40%Position MEDIUM 70%Position HIGH 90%

Follow this procedure to programme the ComfoAir (after installation):1. Set the ComfoAir in programming mode. - ComfoSense Panel: a. Press OK. The display shows SHIFT for 8

seconds. b. Press MENU before the SHIFT text disap-

pears. The display now shows COMF. c. Press or to select INIT. d. Press OK. The display flashes the text INIT

ON. e. Confirm with OK. The display shows OK for

2 seconds. The text INIT is visible in the main menu. - Display: Press simultaneously for at least 3

seconds on " " and " " until “InR” appears on the display.

In programming mode, the bypass and Pre heater valves are always closed. After 30 minutes, the ComfoAir automatically termi-nates the programming mode.

2. Close all windows and outside doors.3. Close all inside doors.4. Check the presence of structural overflow provi-

sions.5. Check if both fans function in the three speed set-

tings.6. Switch the ComfoAir to high speed.7. Install all valves and set the valves according

to the settings given or as set in the reference house.

8. Change the fan settings in P menus P30 to P37 of the digital operating device if required.

Use the chart of the ComfoAir's air specifica-tions to set the fans.

9. In the event that the currently set air volumes still deviate too much: Adjust the valves.

10. Check the entire installation again, after all valves have been set.

11. Switch the ComfoAir (back) to ventilation position 1.

- ComfoSense Panel: a. Press OK. The display shows SHIFT for 8

seconds. b. Press MENU before the SHIFT text disap-

pears. The display now shows COMF. c. Press or to select INIT. d. Press OK. The display flashes the text INIT

EN - 16

ON. e. Confirm with OK. The display shows OK for

2 seconds. - Display: Press simultaneously for at least 3

seconds on " " and " " until “InR” disappears on the display.

2.9 Maintenance by the installerThe following maintenance must be carried out by the installer: Inspecting and (if necessary) cleaning the heat

exchanger; Inspecting and (if necessary) cleaning the fans.A concise explanation of these maintenance activities is given in the paragraphs below.

Check the condensation drain once every 5 years.

Failure to carry out (periodic) maintenance on the ComfoAir ultimately compromises the performance of the ventilation system.

2.9.1 Inspecting and cleaning the heat exchanger

Check the heat exchanger once every 2 years

1. Disconnect the power from the ComfoAir.2. Remove the filter caps from the ComfoAir.3. Release the front panel by unscrewing the screws

(C).

The front swings forward on ceiling-mounted units.

4. Lift front panel from its hinges.5. Disconnect condensation drain.

Take care not to trap your fingers when mounting front panel.

6. Remove the leakage tray by removing the screws (D and E).

The heat exchanger and leakage tray may contain water!

7. Rotate locking nuts (G) on heat exchanger a quarter of a turn.

The heat exchanger may fall downwards on ceiling-mounted units, so ensure the heat exchanger is supported when rotating the locking nuts.

8. Pull strip to remove heat exchanger (D).9. Inspect and if necessary clean the heat ex-

changer.- Use a soft brush to clean the fins.- Use a vacuum cleaner or air gun (no high pres-

sure) to remove dirt and dust.

Always clean against the direction of the air-flow. This prevent dirt from getting stuck in the heat exchanger.

Only Standard heat exchanger:a. Submerge the heat exchanger several times in

C

B

A

17 - EN

hot water (max. 40 °C).b. Rinse the heat exchanger with clean hot tap wa-

ter (max. 40 °C).c. Clasp the heat exchanger between both hands

(on the coloured side surfaces) and shake the water from the heat exchanger.

Only an enthalpy exchanger with a blue co-ver can be washed with water. When having an enthalpy exchanger with a white cover never wash it with water.

Do not use aggressive cleaning agents or solvents.

If the fans or preheater element filter also need maintenance do not re-install the heat exchanger yet.

10. If no more maintenance is necessary install all parts in reverse order, reconnect the pow-er and carry out the self-test in accordance with menu P76.

Fasten the screws to a maximum of 1.5 Nm. This is roughly equal to setting 2 of an ave-rage battery-powered drill.

2.9.2 Inspecting and cleaning the fans

Check the fans once every 2 years.

1. Remove the heat exchanger as instructed in the maintenance chapter of the heat exchanger

2. Remove the inflow nozzle (F) by unscrewing the 2 screws surrounding the scroll casing.

3. Inspecting and if necessary clean the fans (O). - Use a soft brush to clean the fan impellers. - Use a vacuum cleaner to remove dust.

Do not damage the fan impellers or tempe-rature sensor.

4. Install all parts in reverse order.5. Carry out the self-test in accordance with menu

P76.

Fasten the screws to a maximum of 1.5 Nm. This is roughly equal to setting 2 of an ave-rage battery-powered drill.

2.10 MalfunctionsMalfunctions in the ComfoAir are reported as follows: The malfunction alert appears on the ComfoS-

ense panel; The malfunction alert appears on the display; The malfunction indicator on the 3-position

switch lights up.

Malfunction alerts may not appear on the digital oper-ating device in all cases, even though there is a mal-function (or problem). A concise explanation of both types of malfunction (or problem) is given in the fol-lowing paragraphs.

2.10.1 Malfunction alerts on the digital operating deviceIn the event of a malfunction, the corresponding mal-function code will be displayed on the digital operat-ing device of the ComfoAir.

Below is a list of the malfunction alerts on the digital operating device.In the chapter about troubleshooting is explained how to solve these malfunctions

Code Description

A0 NTC sensor TGe is defective.(= geothermal heat exchanger tem-perature)

A1 NTC sensor T1 is defective.(= outside air temperature)

A2 NTC sensor T2 is defective.(= supply air temperature)

A3 NTC sensor T3 is defective.( =return air temperature)

A4 NTC sensor T4 is defective.(= exhaust air temperature)

A5 Malfunction in the bypass motor.A6 Malfunction in the

Pre heater motor.A7 Pre heater does not heat suffi-

ciently.A8 Pre heater becomes too hotE1 Exhaust fan not rotating.E2 Supply fan not rotating.EA1 Enthalpy sensor measures exces-

sive Relative Humidity (RH) values.EA2 No communication between the

enthalpy sensor and the ComfoAir.COMM ERROR

No communication between the ComfoSense panel and the Com-foAir.

FLTR Internal Filter is dirty.FLTR EXT

External Filter is dirty.

EN - 18

2.10.2 3-positionswitchwithmalfunction indicatorThe 3-position switches that are fitted with a malfunc-tion indicator show when a malfunction or filter dirty alert has occurred. Depending on the type of the 3-po-sition switch, this is done in one of the following two ways: 3-position switch with malfunction indicator.

In the event of a malfunction or filter dirty alert the indicator lights up;

Wireless 3-position switch with malfunction indi-cator. The malfunction indicators will light up once this 3-position switch is used. One indicator will light up green to indicate communication has been established. Subsequently, in the event of a malfunctionor filter dirty alert both indicators will flash red 3 times. After that, both indicators will light up green once more.

19 - EN

2.10.3 Whattodointheeventofamalfunction/TroubleshootingBelow are a number of troubleshooting tips for the malfunction alerts described previously which can appear on the digital operating device in the event of a malfunction.

A1 / A2 / A3 / A4NTC sensor

T1 / T2 / T3 / T4is defective

Release the front panelby unscrewing the screws.

Remove the plastic panelin front of the control

circuit board

Lift the front panelfrom its hinges.

Are the connections at the ComfoAir correct?

Reconnect the NTCsensor.

Reconnect thepower to

the ComfoAir.

Yes No

Yes No Is the resistance of the NTC sensor correct?

Replace theNTC sensor.

Replace thecontrol circuit

board .

Set P51 on "0" and P57 to the correct value. (see rating plate)

A7 Malfunction

Reset the malfunction(P74 on 1)

Set P51 on "0"

A6Malfunction

Yes NoWas the

temperature < -27ºC or > 127ºC?


Disconnect thepower from

the ComfoAir. Disconnect the

power from the ComfoAir.


the ComfoAir.


Resistance [KΩ]

MIN. MID. MAX.

10 19,.570 19,904 20,242

15 15,485 15,712 15,941

18 13,502 13,681 13,861

19 12,906 13,071 13,237

20 12,339 12,491 12,644

21 11,801 11,941 12,082

22 11,291 11,420 11,550

25 9,900 10,000 10,100

30 7,959 8,057 8,155

Temperature

[°C]

Resistance table for (NTC) temperature sensors:

Risk of electrocution.

EN - 20

A5 / A6Malfunction in the bypass /

pre heater motor



circuit board

Activate the self-test. (P76 on 1)


Did the bypass / pre heater motor

run Yes


the ComfoAir.


board. Remove themotor


the ComfoAir.

Is the cog of the motordefective?

Yes No

Replace the cogof the motor

Replace themotor

Was there8 VDC power present on the

motor?Yes


the ComfoAir.

Replace themotor

No

No


21 - EN

A7pre heater

does not heat sufficiently.


Remove the plastic panelin front of the control circuit board

Is the resistance of the pre heater element > 100 ?Yes No

Disconnect the power from theComfoAir.

Lift the front panel from its hinges.

Yes NoResistance of

the NTC sensorT1 correct?

Replace thecontrol

circuit board. Replace the

NTC sensor.

Yes NoIs the

resistance ofthe pre heater cable

infinite ?Replace

Pre heatercable

Yes No Are the

connections at the pre heater

correct?

ReplacePre heater.

Reconnect thepre heater.

Install all parts inreverse order.

Reconnect thepower to the ComfoAir.

IsP51 and

P57 set tothe correct

value? Yes No

Set P51 and P57 tothe correct value.

Reset the malfunction (P74 on 1)

Remove the cable of the pre heaterelement from the control circuit

board.

This error will appear when after 3 minutes of switching on the pre heater the temperature increase of T1 is less than 4ºC. This can also happen when there is too much cold air passing through the pre heater. In that case reduce the airflow and re-set the malfunction (P74 on 1).

EN - 22

A8pre heater

becomes too hot. (T1 > 40ºC)



circuit board


Activate the self-test(P76 on 1)

Check the following:- Fan settings (to low?) - Supply valve's (to far closed?) - Supply air ducts (blockages?) - Version settings (P57 correct value?)

NoYes

Did the pre heater

valve open and close?

Refit the (cog ofthe) pre heater

motor.

Disconnect thepower from the

ComfoAir.




Replace cog if it is worn-out.

23 - EN

A0NTC sensor

Tge is defective

Disconnect the power from the ComfoAir.

Are the connections at the ComfoAir correct? Reconnect the

NTC sensor.

Yes No

Yes No

Is P60

set to the correct value?

Yes No

Set P60 to the correct value.


Is the resistance of the NTC sensor correct?

A10 Malfunction

Set P53 on "0".


Replace the NTC sensor.

Install all parts in reverse order.

Reconnect the power to the

ComfoAir.

Replace the Luxeconnection panel




circuit board

EN - 24

E1 / E2 Supply fan / Exhaust

fan not rotating

Release the front panel by unscrewing the screws.


circuit board

Isthere 230 VACpower present on the fan ?

Yes No

Disconnect the powerfrom the ComfoAir.

Replace the control circuit board.

Is a control signal (1,5 - 10 VDC)

present on the fan?

Yes No


the ComfoAir.


board

Replace the fan.(See the maintenance

chapter of the fans)



Activate the self-test(P76 on 1)


25 - EN

EA1Enthalpy sensor

measures excessive Relative Humidity

(RH) values

Ventilate the areaand wait until the moisture content

decreases.

Is thecondensation drain

connecedcorrectly?

Reconnect thecondensation

drain.

Yes No

Isthere a lot of

moisture in the environment? Yes No

Yes No



Refit the leakage tray ofthe ComfoAir.

(See the maintenance chapter of the heat

exchanger)

Wasthere a lot of

moisture in the environment?

,Fil' ,tEr' Internal Filter is dirty

Press “OK” on the

display for at least 4 seconds until the filter warning disappears.


Remove the filter capsfrom the ComfoAir.

Remove the dirty filters from the ComfoAir.

Slide the clean (new) filters back into the ComfoAir. Cleaning: Vacuum the filters with a vacuum cleaner.

Refit the filter caps tothe ComfoAir.

Reconnect the power to the ComfoAir.

EN - 26

EA2No communication

between the enthalpy sensor and

the ComfoAir

Are theconnections

at theComfoAircorrect? Reconnect the

enthalpy sensor.

Yes

IsP59 set to the correct

value? Yes No

Set P59 to the correctvalue.




No

Replace the Luxeconnection panel





circuit board

27 - EN


Are theconnections

at the ComfoSensepanel correct?

Reconnect the ComfoSense panel

to the ComfoAir.


Yes No

Reconnect theComfoAir to the

ComfoSense panel.

Yes No

Check the cablebetween the

ComfoSense panel and ComfoAir.

Issomethingwrong withthe cable?

Yes No

Replace thecable.

Replace theComfoSense panel.

Is acontrol signal present on the

connectionpanel?

NoYes



the ComfoAir.

COMM ERRORNo communication

between the ComfoSense panel and the ComfoAir



the ComfoAir.



the ComfoAir.



Disconnect thepower from the

ComfoAir.

Replace theconnection panel.

Are theconnections

at the ComfoAircorrect?




circuit board


EN - 28

FLTR EXTExternal Filter is dirty

Clean or replace the External filter according

to its own instruction.

FLTR Internal Filter is dirty

Press OK on the ComfoSense panel 2x to reset the FLTR warning.


Remove the filter capsfrom the ComfoAir.

Remove the dirty filters from the ComfoAir.

Slide the clean (new) filters back into the

ComfoAir. Cleaning: Vacuum the filters with a vacuum

cleaner.

Refit the filter caps to the ComfoAir.

Reconnect the power to the ComfoAir.

29 - EN

2.10.4 Malfunctions (or problems) without alertsAn overview of the malfunctions (or problems) without notifications is given below.

Problem/Malfunction Indication Check / action

System switched off Power supply on The control circuit board is defective and must be replaced

No power supply Mains power is offHigh intake tempera-ture in summer

Bypass remains closed Reduce the comfort temperatureComfoAir is still in Winter mode: Bypass remains closed

Checking the Mode of the ComfoAir is possible with special read-out software Wait untill ComfoAir switches to

Summer modeLow intake tempera-ture in winter

Bypass stays open Increase the comfort temperature

Little or no air supply; shower remains damp

Filters blocked Replace the filtersValves blocked Clean the valvesExchanger clogged by dirt Clean the exchangerExchanger frozen Defrost the exchangerFan dirty Clean the fanVentilation ducts blocked Clean the ventilation ducts.ComfoAir is in frost-protectionoperation

Wait until the weather warms up.

Too noisy Fan bearings defective Replace the fan (bearings).Fan settings to high Change the fan (settings)Slurping noise U bend. is empty U bend. does not seal properly

Reconnect the U bend

Whistling noise An air gap somewhere

Seal the air gap

Airflow noise Valves do not close onto duct Valves not open far enough

Reinstall the valvesReset the valves

Condensation leak Condensation drain clogged Unblock the condensation drain.Condensation from exhaust duct does not run into leakage tray

Check whether the connections are correct

Corded 3-position switch not working

Cabling is not correct Check the wiring circuit of the 3-position switch by measuring the voltage: Voltage only on N & L3:

[Fans rotate in position 1] Voltage only on N & L3 & L2:

[Fans rotate in position 2] Voltage only on N & L3 & L1 or

N & L3 & L2 & L1: [Fans rotate in position 3]

Switch is defective

Wireless 3-position switch not working

Battery is discharged Check the battery. Replace the battery (if necessary).

Switch is not correctly tuned. Remove the power briefly from the ComfoAir. Shortly after reconnecting the power tune the switch again

EN - 30

2.11 Service parts

The following table contains an overview of the spare parts available for the ComfoAir.

Number Part Article number1 Fan Right-hand (Green) 4002000182 Fan Left-hand (Red) 4002000193 Control panel 4003000514 Connector panel 4003000315 Temperature sensor T1 / T3 4003000496 Temperature sensor T2 / T4 4003000487 Servo motor & cable (for the bypass and the Pre-heater) 4003000508 Heat exchanger 4004000129 Filter cap 40010002110 Filter 40010001411 Pre-heater 40030006012 Display 400300034

31 - EN

2.12 Wiring diagram: ComfoAir 200 Basic – LEFT-HAND version

M M

N L1L3 L2

RS23

2

BlackRedWhiteBrown

M

WhiteBrownBlue (-)

Yellow (0-10V)White ( )

M

DISPLAY

Bath

room

swi

tch

(vol

t fre

e co

ntac

t)

T3

T2

T1

T4

Preheater valve

Green/ Yellow

BrownBlue

BlueBrown

RedBlackWhiteBrownWhiteBrownWhite ( )Yellow (0-10V)Blue(-)

(L1)

Gre

y(L

2) B

lack

(L3)

Bro

wn(N

) Blu

e

CASING

SUPP

LY

EXHA

UST

RJ45

VENT

.VENT.

FIL

T2/T

4T1

/T3

BYP/

PIE

TRI

VENT

.BS

VENT.

1

T2/T

4T1

/T3

BYP/

PIE

-+

Green/ Yellow

Green/ Yellow

Pre-heater

Bypass valve

(L3) Brown

(N) Blue

1

2

4

SA 1-3V

L2

L1

(L3) Brown

(N) Blue

12

34

+ -LED

SAI 1-3VL2

L1

(L3) Brown

(N) Blue

1

2

4

SA 1-3V

L2

L1

(L3) Brown

(N) Blue

12

34

+ -LED

SAI 1-3VL2

L1

EN - 32

2.13 Wiring diagram: ComfoAir 200 Basic – RIGHT-HAND version

M M

N L1L3 L2

RS23

2

BlackRedWhiteBrown

M

WhiteBrownBlue (-)

Yellow (0-10V)White ( )

M

DISPLAY

Bath

room

swi

tch

(vol

t fre

e co

ntac

t)

T3

T2

T1

T4

Preheater valve

Green/ Yellow

BrownBlue

BlueBrown

RedBlackWhiteBrownWhiteBrownWhite ( )Yellow (0-10V)Blue(-)

(L1)

Gre

y(L

2) B

lack

(L3)

Bro

wn(N

) Blu

e

CASING

SUPP

LY

EXHA

USTRJ

45

VENT

.VENT.

FIL

T2/T

4T1

/T3

BYP/

PIE

TRI

VENT

.BS

VENT.1

T2/T

4T1

/T3

BYP/

PIE

-+

Green/ Yellow

Green/ Yellow

Bypass valve

Pre-heater

(L3) Brown

(N) Blue

1

2

4

SA 1-3V

L2

L1

(L3) Brown

(N) Blue

12

34

+ -LED

SAI 1-3VL2

L1

(L3) Brown

(N) Blue

1

2

4

SA 1-3V

L2

L1

(L3) Brown

(N) Blue

12

34

+ -LED

SAI 1-3VL2

L1

33 - EN

2.14 Wiring diagram: ComfoAir 200 Luxe – LEFT-HAND version

J1

RS485Entalpy

RS485Hybalans

RS232KFB

12V

0-10

V

A1

A2

GN

D12

V

B A GN

D12

V

B A GN

D12

V

1(R

X)

2(T

X)

GN

D

RS232PC

PCB Comfo-

SenseHybalans

0-10

V

M

M

RS232

Bla

ck

Re

dW

hite

Bro

wn

M

Wh

iteB

row

nB

lue

(-)Y

ello

w (0

-10

V)

Wh

ite ( )

M

DIS

PL

AY

Bathroom switch (volt free contact)

Pre

-he

ate

r

T3

T2

T1

T4

Pre

-he

ate

r va

lve

Gre

en

/ Ye

llow

Bro

wn

Blu

e

Blu

e

Bro

wn

Re

dB

lac

kW

hite

Bro

wn

Wh

iteB

row

nW

hite

( )Y

ello

w (0

-10

V)

Blu

e(-)

(L3) Brown

(N) Blue

SUPPLY

EXHAUST

RJ45

VENT.

VE

NT.

FILT2/T4T1/T3BYP/PIE TRI

VENT. BS

VE

NT.

1

T2/T4T1/T3BYP/PIE

- +

Gre

en

/ Ye

llow

Gre

en

/ Ye

llow

By

pa

ss

va

lve

EN - 34

2.15 Wiring diagram: ComfoAir 200 Luxe – RIGHT-HAND version

J1

RS485Entalpy

RS485Hybalans

RS232KFB

12V

0-10

V

A1

A2

GN

D12

V

B A GN

D12

V

B A GN

D12

V

1(R

X)

2(T

X)

GN

D

RS232PC

PCB Comfo-

SenseHybalans

0-10

V

M

M

RS232

Bla

ck

Re

dW

hite

Bro

wn

M

Wh

iteB

row

nB

lue

(-)Y

ello

w (0

-10

V)

Wh

ite ( )

M

DIS

PL

AY

Bathroom switch (volt free contact)

T3

T2

T1

T4

Pre

he

ate

r va

lve

Gre

en

/ Ye

llow

Bro

wn

Blu

e

Blu

e

Bro

wn

Re

dB

lac

kW

hite

Bro

wn

Wh

iteB

row

nW

hite

( )Y

ello

w (0

-10

V)

Blu

e(-)

(L3) Brown

(N) Blue

SUPPLY

EXHAUST

RJ45

VENT.

VE

NT.

FILT2/T4T1/T3BYP/PIE TRI

VENT. BSV

EN

T.

1

T2/T4T1/T3BYP/PIE

- +

Gre

en

/ Ye

llow

Gre

en

/ Ye

llow

Pre

-he

ate

r

By

pa

ss

va

lve

35 - EN

2.16 EEC declaration of conformity

Zehnder Group Nederland B.V.Lingenstraat 28028 PM Zwolle-NLTel.: +31 (0)38-4296911Fax: +31 (0)38-4225694Company register Zwolle 05022293

EEC declaration of conformity

Machine description : Heat recovery units: ComfoAir 200 series

Complies with the following directives : Machinery Directive (2006/42/EEC) Low Voltage Directive (2006/95/EEC) EMC Directive (2004/108/EEC)

Zwolle, 15-01-2014Zehnder Group Nederland B.V.

O. Schulte,Director Production Zwolle

ZGN

L-M

anua

l_40

0148

80, V

0117

, EN

, Sub

ject

to c

hang

e

Zehnder Comfosystems • A division of Zehnder Group UK Ltd

Unit 1, Brookside Avenue • Rustington West Sussex • BN16 3LF

T +44 1903 777 333 • F +44 1903 782 398

[email protected] • www.zehnder.co.uk/comfosystems

ComfoAir 200 Installer manual

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Transcript of ComfoAir 200 Installer manual